CN103358308A - Robotic weld gun orientation normalization - Google Patents
Robotic weld gun orientation normalization Download PDFInfo
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- CN103358308A CN103358308A CN2013101772033A CN201310177203A CN103358308A CN 103358308 A CN103358308 A CN 103358308A CN 2013101772033 A CN2013101772033 A CN 2013101772033A CN 201310177203 A CN201310177203 A CN 201310177203A CN 103358308 A CN103358308 A CN 103358308A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
- B23K11/115—Spot welding by means of two electrodes placed opposite one another on both sides of the welded parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
- B23K11/25—Monitoring devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/30—Features relating to electrodes
- B23K11/31—Electrode holders and actuating devices therefor
- B23K11/314—Spot welding guns, e.g. mounted on robots
- B23K11/315—Spot welding guns, e.g. mounted on robots with one electrode moving on a linear path
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Abstract
A method for controlling a welding robot having a servo gun with a movable tip and a fixed tip includes the steps of separately contacting a surface of a part with the movable tip to measure a base test point and an at least two additional test points displaced from the base test point. Two non-collinear vectors are calculated from the at least two additional test points. A normal vector is calculated from the two non-collinear vectors. An angle between the original servo gun orientation and the normal vector is determined. An orientation of the servo gun may be corrected, for example, if the angle is within user specified tolerances.
Description
Technical field
The present invention mainly relates to a kind of welding robot system and method, and more specifically, relates to a kind of bearing calibration of orientation of spot welding servo torch of welding robot system.
Background technology
Welding robot system with spot-welding gun for example, is described in the publication number of Takahashi etc. is the U.S. Patent No. 5898285 of the U.S. Patent application of No.2011/0089146 and Nagasawa etc.A kind of typical spot welding servo torch comprises a kind of main body with fixed electrode head and movable electrode head.The fixed electrode head is described movable electrode head and arranging vis-a-vis.The fixed electrode head is with respect to the main body of spot-welding gun and normally Immobile, and the movable electrode head is installed on the main body and during welding operation and is opened and closed.
For good welding quality, two electrode tips all must push a kind of parts with the power that equates.If electrode tip does not contact/touch described parts, then need again teaching or teaching to proofread and correct.Yet it is consuming time that the teaching of welding robot is proofreaied and correct.
Known automatic teaching bearing calibration be can not determine welding gun electrode whether perpendicular to the surface of soldered parts, so the orientation of spot-welding gun is not corrected.Misorientation, wherein the spot welding servo torch is not orthogonal to parts to be welded, causes undesirably inhomogeneous current density on inhomogeneous power distribution, the whole solder joint, and finally causes bad/poor welding quality.It is difficulty and consuming time that misorientation is proofreaied and correct, particularly when one of welding gun electrode as seen be not fully the time.
The method that needs constantly a kind of orientation be used to proofreading and correct a kind of spot-welding gun comprises and determines normal vector with respect to the surface of parts to be welded.Desirably, this information is used to proofread and correct the orientation of described spot-welding gun before welding operation.
Summary of the invention
According to disclosed content immediately, be surprised to find a kind of method for check point welding gun orientation, comprise with respect to the surface of parts to be welded and determine normal vector, and before welding operation the orientation of check point welding gun.
In a kind of illustrative embodiment, present disclosed method provide automatically be identified for servo torch correct/proofread and correct the ability of orientation (for example, the normal direction orientation), do not need outside sensor.The orientation bearing calibration can be activated to proofread and correct an independent point via a kind of program editor, perhaps proofreaies and correct whole program via a kind of numeral input.In the correction to program pattern, robot sequentially/sequentially moves through welding procedure and determines suitable orientation, and the orientation of correcting servo welding gun.A kind of welding procedure can be performed during trimming process, to increase the flexibility of this function.For example, the correction to program pattern can be used during manufacturing or off-line procedure as required.The method can also generate a kind of point or position, the amount of correction and document of other data that once was corrected of having reported.If necessary, position correction can be limited to specific tolerance.
The method also can use the movable electrode that comes from servo torch carrying out the perturbing torque feedback of at least one motor of control with in detection part position, three-dimensional a plurality of somes place.Wherein found a kind of normal vector based on the position of multiple spot, the robot orientation can correspondingly be changed.In welding procedure, at least one in the position of robot and the orientation can be updated or record.
Should be understood that, the plane around the spot welding point may change or may not exist.And when the test point that moves to around the spot welding point, the robots arm may collide with other object in parts in the working cell or the working cell.In brief, the real surface of the existence that can be used for detecting at each some place is limited, namely, depends on a little.Like this, search pattern can be selected based on available surface.These pattern utilisation point instructions and designated/determine (for example, in running time, in program), the perhaps selection (for example, off-line is realized by the operator, via program editor) by search configuration.
The search pattern shape of some can be used.The search pattern shape has comprised the test point in the center, to obtain following benefit:
The servo torch that is used for search of-to some extent minimizing is opened distance;
-use identical detection threshold at all test point places;
-be used for the reference value of crosscheck/checking; And
-use identical side-play amount and welding gun to open distance at all test point places.
In one embodiment, a kind of method for controlling having a kind of welding robot that is possessing the servo torch of movable electrode head and fixed electrode head, may further comprise the steps: utilize surface that the movable electrode head contacting parts measuring the basic test point, and at least two additional test points that are shifted and open from basic test point.From the measurement of additional testing point, generate two non-collinear vectors, and from these vectors, calculated normal vector.The orientation of servo torch is corrected for this reason normal vector.
In a further embodiment, additional test point provides predetermined search pattern shape.Again, the orientation of servo torch is corrected for this reason normal vector.
In another embodiment, can be based on the contrast of the orientation of servo torch and normal vector and is corrected in the position of the servo torch in the robot welding program.
Description of drawings
When considering when the reference accompanying drawing, above-mentioned, and other advantages of the present invention to one skilled in the art, will become apparent from the detailed description that regards to down preferred embodiment, wherein:
Fig. 1 is according to the illustrating of the robot welding gun of a disclosed embodiment, and further shows for the robot welding gun and be orientated normalized method;
Fig. 2-the 4th, the illustrating of the movable electrode head of the welding gun of robot shown in Fig. 1, and further show progressively orientation correction, position correction and range correction and think that servo torch provides phase required spot welding position;
Fig. 5 is illustrating of the various test position patterns that can be carried out by robot shown in Fig. 1 welding gun, uses described be used to being orientated normalized method; And
Fig. 6 is the movable electrode head of robot welding gun shown in Fig. 1 and illustrating of fixed electrode head, and further show use the perturbing torque feedback come from the motor of controlling movable electrode and in three dimensions detection part position progressively;
Fig. 7 is the flow chart be orientated normalized method and use the robot welding gun shown in Fig. 1 of being used for that illustrates according to a specific embodiment of the present disclosure.
The specific embodiment
Following description only is exemplary in essence, and is not to be intended to be used to limiting content of the present disclosure, application or use.Should be understood that, in the whole accompanying drawing, corresponding Reference numeral is also being indicated similar or corresponding parts or feature.About disclosed method, the step of displaying is exemplary in essence, and thereby, not essential or critical.
Fig. 1 shows the robot welding system 100 who uses according to method of the present disclosure.Robot welding system 100 has comprised a kind of welding robot 102 with servo torch 104, and servo torch 104 has movable electrode head 106 and fixed electrode head 108.Welding robot 102 is configured to weld a kind of parts 110, such as a kind of metal decking for automobile.Also can utilize robot welding system 100 of the present disclosure to weld the parts 110 of other type.
For example, movable electrode head 106 can be connected at least one motor 111, and motor 111 is configured in order to drive described movable electrode head 106 in the direction towards workpiece 110.This at least one motor 111 can be servomotor, for example, is configured to provide the automatic feedback for Accurate Position Control.Those skilled in the art also can use other means to drive described movable electrode head 106 as required.
As illustrating further among Fig. 1, method of the present disclosure comprises step: utilize the surface 112 of the described parts 110 of movable electrode head 106 contacts to measure a kind of basic test point 114, and utilize subsequently 106 contacts described surperficial 112 of movable electrode head to measure at least two additional test points 116,118,120,122 of opening from 114 displacements of basic test point.Calculate two non-collinear vectors from described at least two additional test points 116,118,120,122.From these two vectors, calculate normal vector, and determine the angle between the vector of the orientation of this normal vector and initial servo welding gun 104.
The method can further comprise the step of regulating the orientation of described servo torch 104 with respect to normal vector.This step can be carried out conditionally, based on the angle between initial orientation (vector) and normal vector.For example, if the angle between the initial orientation of normal vector and servomotor is very large, then orientation is proofreaied and correct and can be skipped.In the scope of present disclosure, can also use other adjusting type of servo torch 104 orientations.
In the specific embodiment shown in Fig. 2-4, the movable electrode head 106 of servo torch 102 can experience a kind of orientation progressively and proofread and correct (Fig. 2), position correction (Fig. 3) and range correction (Fig. 4), so that required spot welding position 124 to be provided for servo torch 102.Particularly, in case normal vector is calculated, then servo torch 104 can be moved to for the normal direction of required spot welding 124 or the position of correction.Movable electrode head 106 also can be determined with respect to the angle of normal vector, and after rotation, correspondingly movable electrode head 106 is made adjusting and contact to keep with parts 110.
Referring now to Fig. 5, method of the present disclosure may further include specifies a kind of test point shape, calculates the step of normal vector according to it.For example, the test point shape can be determined by the shape on the surface 112 of parts 110 to be welded.Robot welding system 100 can generate the test point shape by with predetermined pattern servo torch 104 and movable electrode head 106 being moved at least two additional test points 116,118,120,122 from basic test point 114.The test point shape is processed rapidly before welding operation begins.For example, the speed of movable electrode head 106 from a position movement to another position can be 250mm/sec.In the scope of disclosure, can also use other the speed that is used to form the test point shape.
Need to be in a plurality of different corrections for direction orientations situation of (such as with respect to servo torch 104 direction and transversely externally), the test point shape can comprise basic test point 114, and in the additional test point 116,118,120,122 at least three.As nonrestrictive example, the test point shape can comprise one of triangle 130 of rhombus 126, the triangle 128 that outwards points to and inwardly sensing.Need to just be orientated the single direction colonel therein in the situation of (such as with respect to servo torch 104 only on externally the direction or only in the horizontal), the test point shape can comprise basic test point 114 and two additional test points 116,118.As nonrestrictive example, the test point shape can comprise one of the line 132 of outside sensing and line 134 of laterally sensing.
In another example, the test point shape can generate by providing around the search radius of basic test point 114, at least two additional test points 116,118,120,122 tested on described radius.In one embodiment, the acquiescence radius approximately be derived from basic test point 114 about+/-5mm.Can also use varying number and the configuration of the additional test point of having of other type 116,118,120,122, and the test point shape of different search radius.
It is to be further understood that, at least two additional test points 116,118,120,122 can be alignd with parts 110, and can have the predetermined gap for rotation error based on the translation distance between the additional test point 116,118,120,122 of basic test point 114 and at least two.The predetermined gap that can select for this rotation error each specific parts 110 as required.
Determine that on the surface 112 of parts 110 this method can comprise the distance of measurement between movable electrode head 106 and surperficial 112 in basic test points 114 and at least two additional test points 116,118,120,122 the process.Particularly, as shown in Fig. 2-4, this distance can be the distance on Z-direction.For example, for each original and additional test point 114,116,118,120,122, until occur to contact the distance that then can record on the Z-direction with surface 112.A plurality of measured distances can be used to respect to the surface 112 of parts 110 and definite plane and normalized vector.
In a kind of specific embodiment, during the process of the step that is contacting parts 110, detect described basic test point 114 and at least two additional test points 116,118,120,122 step can comprise a kind of electrical continuity (electrical continuity) measurement.For example, when parts 110 are grounded, when since movable electrode head 106 with the contacting of parts 110 of ground connection so that electrode voltage drops to predetermined value when below horizontal, movable electrode head 106 is confirmed to be and touches surperficial 112.As shown in fig. 1, as nonrestrictive example, electrical continuity is measured can be communicated to computer 133 via holding wire 131, such as a kind of servo torch controller or a kind of robot controller.Predetermined voltage and device that be used for to measure the voltage of movable electrode head 106 can be selected by those skilled in the art as required.
In another embodiment, as shown in fig. 1, during the process of step of the described parts 110 of contact, detect described basic test point 114 and at least two additional test points 116,118,120,122 step can comprise that a kind of non-contact optical sensor 135 is connected with computer 133 by holding wire 137.Non-contact optical sensor 135 can measure can be between movable electrode head 106 and parts 110 surfaces 112 the distance on Z-direction.For example, non-contact optical sensor 135 can be in photoelectric tube/electric eye (electric eye) and the laser beam detector one of at least.The non-contact optical sensor 135 that those skilled in the art can select other types as required is to be used for measuring contacting of movable electrode head 106 and parts 110 surfaces 112.
During the step of the described parts 110 of contact, detect described basic test point 114 and at least two additional test points 116,118,120,122 step state movable electrode head 106 by measurement in motor 111 places perturbing torque and feed back and carry out.The perturbing torque feedback also can be communicated to computer 133 by holding wire 131 as required, or by another way.
Fig. 6 shows for each a kind of case solution detection order of using perturbing torque to feed back in the position 116,118,120,122.At initial position, when the Location-Unknown on the surface 112 of parts 110 (shown in the dotted line among Fig. 6), servo torch 104 can be opened to certain scheduled backup distance.Then servo torch 104 and movable electrode head 106 are accelerated to the next position, and the speed of servo torch is detected.Then by driving described movable electrode head 106 towards parts 110, then servo torch 104 begins to close.The movement of movable electrode head 106 facilitates and realizes reading of torque standard because movable electrode head 106 begin mobile after described torque readings/read become stable.After having obtained the torque standard, parts 110 beginnings are from detecting and finishing when detecting the torque feedback different from the torque standard, and it indicates that movable electrode head 106 has contacted the surface 112 of described parts 110.Use thus perturbing torque feedback and provide the foundation test point 114 and at least two additional test points 116,118,120,122 measurement, it does not advantageously need to measure with independent sensor or equipment surperficial 112 distance.
In the scope of the present disclosure, can also use other mode to be used for measuring basic test point 114 and at least two additional test points 116,118,120,122 distance.
With reference to accompanying drawing 7, show a specific orientation normalization method 136 that uses robot welding gun 102.After a kind of initialization step 138, wherein the user has begun to be used for the orientation normalization method 136 of parts 110 to be welded, determines and has stored the current location (CURPOS) of described robot 102 and the current location of servo torch 104 at the normalization method of orientation described in the baseline step 140 136.Movable electrode head 106 is moved into the surface 112 of parts 110 subsequently in initial position step 142, its test point 114 that provides the foundation.In test shape step 144, servo torch 104, and similarly then movable electrode head 106 is moved at least two additional test points 116,118,120,122 each, as described further below.From test point measurement two the non-colinear vectors of letting it pass of falling into a trap.In normal vector calculation procedure 148, normal vector is from the vector of two measurements and be calculated.The calculating that limits in advance includes, but not limited to the calculating shown in Fig. 7.In step 150, determined the rotational angle between initial orientation (vector) and normal vector.If the user allows occur to proofread and correct, then subsequently in aligning step 152, servo torch 104 moves to the coordinate that calculates, and is defined/is limited by normal vector.In completing steps 154, servo torch 104 is opened and does the preparation of carrying out welding operation at parts 110.
The method has further comprised the step of proofreading and correct the position of described servo torch 104 in the robot welding program, for example, carries out at the robot controller (not shown).The position that can in program, proofread and correct servo torch 104 in the described program based on the contrast of angle between the initial orientation (vector) of servo torch 104 and normal vector.Pending correction to program except allowing servo torch 104 and the standardization of movable electrode head 106 with respect to the orientation on workpiece 110 surfaces 112, perhaps also can be used as the normalized a kind of selection/replacement scheme of orientation as required.
Advantageously, for example, method of the present disclosure provides does not use external sensor, and automatically determine to proofread and correct, for example normalized, is used for the ability of orientation of the servo torch 104 of robot 102.Owing to having avoided misorientation, be the situation that servo torch 104 is not orthogonal to parts 110 at the error place wherein, then at the power skewness, at whole solder joint inhomogeneous current density is arranged, and finally causing adverse effect aspect the bad welding quality decline.
Although in order to illustrate that purpose of the present invention has shown some representational embodiment and details, will it is evident that for those skilled in the art, can carry out various variation in the situation that do not break away from disclosure scope, it is further described in claims below.
Claims (20)
1. one kind is used for the method that butt welding machine device people controls, and welding robot has a kind of servo torch that possesses movable electrode head and fixed electrode head, and the method comprising the steps of:
The surface of parts is contacted, to measure a kind of basic test point with the movable electrode head;
Surface and movable electrode head are contacted, to measure at least two additional test points opening from the displacement of basic test point;
Calculate two non-collinear vectors from least two additional test points;
Calculate a kind of normal vector from two non-collinear vectors; And
Relatively between the orientation of initial servo welding gun and the angle between the normal vector.
2. according to claim 1 method further comprises the step of regulating the servo torch orientation with respect to normal vector.
3. according to claim 1 method, wherein standardization orientation is recorded in the robot welding program.
4. according to claim 1 method further comprises based on the shape of parts surface and specifies a kind of step of test point shape.
5. according to claim 4 method, wherein the test point shape comprises basic test point and two additional testing points.
6. according to claim 5 method, wherein servo torch to be oriented in a direction modulated.
7. according to claim 4 method, wherein the test point shape comprises basic test point and at least three additional testing points.
8. according to claim 7 method, wherein servo torch to be oriented in a plurality of directions modulated.
9. according to claim 4 method, wherein the test point shape is rhombus, the triangle that outwards points to and the triangle that inwardly points to, the line that outwards points to and horizontal one of Direction Line.
10. according to claim 1 method, wherein at least two additional test points are alignd with parts, and have based on the translation distance between the additional test point of basic test point and at least two, for the predetermined gap of rotation error.
11. method according to claim 1 further comprises such step: during the step of the described parts of contact in the additional distances of test point place measurement between movable electrode head and surface of basic test point and at least two.
12. method according to claim 1 further comprises such step: during the step of the described parts of contact, utilize the perturbing torque of movable electrode head to feed back and detection basic test point and at least two additional test points.
13. method according to claim 1 further comprises such step: during the step of the described parts of contact, utilize electrical continuity to measure and detection basic test point and at least two additional test points.
14. method according to claim 13, parts ground connection wherein, and when owing to contacting with the surface of the parts of ground connection so that electrode tip voltage drop when below horizontal to predetermined value, the movable electrode head is confirmed as and is being contacted the surface.
15. method according to claim 1 further comprises such step: so that with step that parts contact during utilize the non-contact optical sensor to detect the additional test point of described basic test point and at least two.
16. method according to claim 15, wherein the non-contact optical sensor measurement goes out the distance between the surface of movable electrode head and parts.
17. method according to claim 15, wherein the non-contact optical sensor is at least a in electric eye and the laser beam detector.
18. method according to claim 1 further comprises such step: proofread and correct the position to servo torch based on the angle between initial servo welding gun orientation and normal vector and in the robot welding program.
19. one kind is used for the method that butt welding machine device people controls, welding robot has a kind of servo torch that possesses movable electrode head and fixed electrode head, and the method comprising the steps of:
The surface of parts is contacted, to measure a kind of basic test point with the movable electrode head;
The surface is contacted with movable electrode, and to measure at least two additional test points opening from the displacement of basic test point, basic test point and at least two additional test points provide a kind of predetermined search pattern shape;
Calculate two non-collinear vectors from basic test point and at least two additional test points;
Calculate normal vector from two non-collinear vectors;
Compare the angle between initial servo welding gun orientation and normal vector; And
The orientation of regulating servo torch with respect to normal vector.
20. one kind is used for the method that butt welding machine device people controls, welding robot has a kind of servo torch that possesses movable electrode head and fixed electrode head, and the method comprising the steps of:
The surface of parts is contacted, to measure a kind of basic test point with the movable electrode head;
The surface is contacted with movable electrode, and to measure at least two additional test points opening from the displacement of basic test point, basic test point and at least two additional test points provide a kind of predetermined search pattern shape;
Calculate two non-collinear vectors from basic test point and at least two additional test points;
Calculate normal vector from two non-collinear vectors;
Compare the angle between initial servo welding gun orientation and normal vector; And
The position of in the robot welding program, proofreading and correct described servo torch based on the orientation of servo torch and the comparison between the normal vector.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US13/433,850 US9144860B2 (en) | 2012-03-29 | 2012-03-29 | Robotic weld gun orientation normalization |
| US13/433850 | 2012-03-29 |
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| CN103358308A true CN103358308A (en) | 2013-10-23 |
| CN103358308B CN103358308B (en) | 2017-03-01 |
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| CN201310177203.3A Active CN103358308B (en) | 2012-03-29 | 2013-03-29 | Robotic gun orientation standardization |
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| US (1) | US9144860B2 (en) |
| JP (2) | JP2013202692A (en) |
| CN (1) | CN103358308B (en) |
| DE (1) | DE102013103137B4 (en) |
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Also Published As
| Publication number | Publication date |
|---|---|
| US20130256278A1 (en) | 2013-10-03 |
| JP2013202692A (en) | 2013-10-07 |
| CN103358308B (en) | 2017-03-01 |
| JP2020073283A (en) | 2020-05-14 |
| DE102013103137A1 (en) | 2013-10-02 |
| DE102013103137B4 (en) | 2024-05-29 |
| US9144860B2 (en) | 2015-09-29 |
| JP7174683B2 (en) | 2022-11-17 |
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